BRINGING THE SIMPLICITY OF DIGITAL PRINTING TO FLEXO!

Transcription

1 BRINGING THE SIMPLICITY OF DIGITAL PRINTING TO FLEXO!

2 Index What is REVO Digital Flexo Revolution? Details of Technology What do I need for REVO Digital Flexo? What are the benefits? REVO minimum specifications REVO Frequently Asked Questions The future of REVO

3 What is REVO Digital Flexo Revolution? REVO Digital Flexo Revolution is a Project Team of leading companies in the Flexo industry, promoting a new manufacturing method to digitize the flexographic process, making it uniquely consistent, cost effective and strengthen the leadership of Flexo in the Labels and Packaging industry. Why? Because 7 colour separation is the FUTURE for the Labels and the Packaging industry Because UV Flexo is the most consistent printing technology Because Flexo presses are easy to operate andcontrol

4 What is REVO Digital Flexo Revolution? The Revo Members Product Revo Activity Converter of Labels and Packaging Field Test and Validation of the REVO Digital Flexo process Anilox rollers Anilox rollers suitable for REVO specifications Helios 100% inspection Press Control & Quality Control Polymer plates and pre-press HW Flexo plates suitable for REVO specifications Pre-press software and hardware 7 colours separation SW and control HW suitable for REVO specifications Printing Inks Flexo inks suitable for REVO specifications Printing and converting machines Digital automation for REVO printing and converting specifications Labels and Packaging substrates Substrates suitable for REVO specifications

5 What is REVO Digital Flexo Revolution? REVO Members cooperate to provide a common, easy off-the-shelf turn-key solution to converters, maximizing the advantages of the latest digital progress in the Flexo industry. Each partner contributes to develop existing flexo technologies and specific integrated solutions for the REVO project. Main focus of developments, and target objectives are: 7 Colour separation Digital Flexo Automation Next Generation UV Flexo inks Next Generation Digital Plates Next Generation Anilox rollers Next Generation Press control

6 Details of REVO Technology REVO Digital Flexo is : UV Flexo for Labels and Packaging Extended colour gamut (7 colours to match PMS colours) Digital Automation in printing and converting. REVO manufacturing method integrates the latest developments in UV Flexo, extended colour gamut and digital automation technologies. Traditional manual flexo operations like ink colour matching, pressure and register settings, exchanging of print cylinders are fully automated and digitally controlled. PMS colours are digitally prepared via Software, not in the ink kitchen. Inks and anilox rollers are never changed in the press. With 7 colours most PMS colours are reproduced. Hundreds of PMS colours can be printed inside the same job. With an extremely vibrant quality on process images. As a result, set up waste and time are comparable to typical Digital presses.

7 Details of REVO Technology Easy: consistency across print operators as printing and converting operations are digitally automated. Clean: never change inks and anilox. No washing, no cleaning, no ink handling. Consistent: always 7 inks in the press, producing always the same quality and PMS colours. Perfect for short runs 1: no colour matching on press, digital colour matching. Perfect for short runs 2: digital set up, digital run. Profitable: less ink consumption, less wastes, close to 100% press up-time.

8 Details of REVO Technology Print quality: real and "vibrant" astonishing 7 colours pictures at 80 l/cm. Unique images: Hundreds of PMS colours printed in one job, with no additional cost. Fast 1: digital job change-overs, 4 job changes per hour or more. Fast 2: printing at 10 m/min or 180 m/min without any change in ink density. Flexible: no limits, print on every Packaging substrate. Digital: One digital work flow for typical Digital and REVO Digital Flexo printing.

9 Details of REVO Technology REVO Digital Flexo VS Typical Digital Printing q Comparable waste and set up time q Comparable print quality q Improved flexibility q Improved production speed q Improved consistency q Improved press up-time q Independent from press supplier q Printing on every substrate

10 What do I need for REVO Digital Flexo? REVO- Digital Flexo Revolution is a new manufacturing method in flexography developed for the full digitalisation of the flexo process. The REVO Project collects a Team of global suppliers of material and technologies, ADARE, APEX, AVT, DUPONT, ESKO, FLINT GROUP, GIDUE, UPM RAFLATAC, working together to introduce the REVO Digital Flexo Revolution in the Labels and Packaging industry. The REVO Team developed the integrated REVO Set of Technologies, which includes: Flexocure Ancora Low Migration UV inks, Cyrel DFUV and DPR photopolymer plates, GTT anilox rollers, Equinox separation pre-press, Fit range of substrates, Infinite Flower print units, Helios II pressure control & 100% inspection. REVO Method and REVO Set of Technologies are immediately available as an off-the-shelf turnkey package. REVO DIGITAL FLEXO Revolution is accessible to every Labels and Packaging converter in the industry, from therevo Team members worldwide.

11 What do I need for REVO Digital Flexo? DuPont Cyrel Digital Photopolymer Plate Technology Cyrel DFUV is a thermal process plate that comes to color quickly and prints smooth and dense solids, without compromising dot gain, highlights or resolution. It performs very well with fine screens Cyrel DFUV is specifically designed for shorter print runs using UV inks on high priced stock where minimizing the startup waste is essential. In combination with Cyrel DigiFlow the new digital flat top dot technology, 80 lines per cm screen count is the new achievable standard, changing again the rules of our industry. Extended color gamut technologies take great advantage of the improved ink laydown and the reduced graininess. To achieve the best possible result, the 7 colors overprint needs to be printed with high line count. Consequently the REVO technology is based on extremely fine screen rulings of the 7 colors which are printed on top of each other. Full tones are printed as very fine invisible vignettes which simulate, for the human eye, the effect of a full solid. The new generation Cyrel DFUV digital plate provides the requested quality, thus a wide gamut of PMS colors can be reproduced, without changing the inks in the press.

12 What do I need for REVO Digital Flexo? Esko 4 to 7 Colours Separation SW and HW Control With Equinox colour separation software, Esko offer a total solution for the implementation of extended gamut printing. Equinox standardizes your printing presses on any set of 4 or 7 inks of your choice. With this, your press changeover workload between jobs isreduced to merely changing printingplates. Extended colour gamut is the most logic solution for the flexo industry going digital. 4 or 7 inks always in the press. No need to change anilox or ink. No special colours, no colour matching, no waste of substrate, no press down-time. Most PMS colours can be reproduced by printing 4 or 7 colours on top of each other. With 7 colours separation pre-press can digitally reproduce up to 90% of PMS colours.

13 What do I need for REVO Digital Flexo? Next Generation FLINT GROUP UV Flexo Inks REVO process needs top consistency printing quality and high colour density to achieve the best performances. New generation Flexocure ANCORA Low Migration UV Flexo inks support the REVO Digital Flexo Revolution with migration levels compatible with the tightest food packaging health rules, high pigmentation, consistent ink transfer, consistent density properties, giving to REVO projects a wide range of graphic possibilities, and excellent consistency performances.

14 What do I need for REVO Digital Flexo? Next Generation APEX Anilox Rollers UV flexo ink and digital flexo plates deliver fantastic and consistent quality. But inconsistent ink transfer, and inconsistency between anilox rollers might endanger the digital consistency of the REVO standards. In a 7 colour separation a key factor is to provide accurate consistency of the lay down of the 7 colours. New slalom engraving technologies developed recently on new generation GTT Anilox Rollers are able to overcome some inconsistency of standard anilox designs. REVO standards need a predictable ink density which can be achieved thanks to the new anilox rollers design which delivery ink transfer with less than 1% tolerance. New slalom anilox roller s technology provide fundamental contribution to the REVO digital new standards. A further advantage of REVO technology is that less ink transfer is needed, to achieve the same level of opacity. By overlapping 7 vignettes instead of using full solids, ink transfer is reduced, as well as ink consumption. Ink costs, curing costs are reduced, and the whole PMS process is consistent and repeatable.

15 What do I need for REVO Digital Flexo? UPM Raflatac FIT Range of Substrates The REVO Digital Flexo Revolution is setting a global standard, and this calls for consistency from all partners. Proprietary production technologies guarantee the same consistency of surface quality and ink reception in every corner of the world. Among the benefits of REVO are cost-efficiency and a reduction in waste, and next generation substrates development supports this with materials like the Fit range, which are engineered for a more sustainable use of resources, cost-efficiency and process-efficiency while retaining optimal performance. New substrates and printing technology are progressing in parallel with the same objectives.

16 What do I need for REVO Digital Flexo? AVT Press Control and Inspection Technologies AVT Helios II with presco NW is the revolutionary solution for automatic press pressure control and can also be specified with the optional 100% automatic inspection technology and all currently available Helios features. The Helios II fully automatic makeready pressure control solution is achieving excellent results while meeting the vision of advancing a digital revolution throughout the greater flexo industry. Helios II 100% inspection is the leading solution for total print quality control and through the development of the new image based make-ready pressure control, in cooperation with GIDUE Digital Automation, is able to take a traditional, craft-based process and turn it into a consistent and repeatable digital function. This new level of automation will remove another variable from the press set up procedure, fully supporting the goals of the REVO method and standards of Digital Flexo manufacturing.

17 What do I need for REVO Digital Flexo? GIDUE: A new Digital Automation press for REVO Standards Extensive Digital Automation in the printing press is needed to collect all the opportunities of the new REVO digital flexo process. On the printing and converting sections, servo motors and digital HD Cameras substitute the eyes and the fingers of the operator with digital eyes and digital fingers. The new generation presses exchange the print and diecutting cylinders from old to new job fully automatically, without operator. Digital Automation in flexo presses completes the REVO digital chain from pre-press, to plates, to inks, to anilox and finally to printing and converting, to achieve a full REVO digitalization of the flexo process.

18 What are the benefits? Cost reduction: less substrate, less inks, less time are wasted for colour matching in the press. Up to 90% of PMS palette is reproduced with combination of the fixed colours in the press. less ink is needed to print PMS colours (up to 50%). less substrate is wasted during set-up in the press due to Digital Automation more up-time of the press is achieved due to down-time reduction for colour matching, print and die-cutting cylinders change, press set-up, press inconsistency during production. no additional cost for substrates pre-treatment

19 What are the benefits? Consistency: process parameters are digitised throughout the entire workflow from pre-press to print. The full process is under REVO digital control. operators skills are not required for colour matching. anilox engraving and inks are optimized for consistent performances. digital automation on press greatly reduces the variables caused by operator s skills. colour density isconsistent from 10 m/min to 180 m/min

20 What are the benefits? Quality: Extended colour gamut with 7 colours (CMYK + Orange, Green, Violet) provide vibrant effects on pictures with natural and realistic images. HD Flexo with 80 lines per cm (200 LPI) become standard, taking flexo to a higher print quality level.

21 What are the benefits? Digital flexibility: the same file can be printed on a Digital or a REVO Digital Flexo press, with similar quality and costs. Production flow can be similar to a Digital press, with I. frequent job changes, II. last minute job planning III. fast speed to market IV. reduced minimum order quantity Graphic flexibility: a single job can contain hundreds of PMS colours, without additional print stations. REVO allows printers to combine multiple labels on the same plate.

22 First REVO Testimonial Adare is a UK leading converter who has experienced REVO technology in real production. The advantage of REVO technology, which we are beta-testing as a Labels and Packaging converters since last year, is inherent to the digital control of all variables. We have encountered dramatic cost reductions in substrate waste, press down-time, ink consumption. It is clear that colour matching for a converter is the greatest problem, in real life production. With REVO digitally optimized technologies we can achieve repeatable and predictable PMS shades. A digitally automated press makes the rest in terms of fast turnaround. Thus we have changed our production structure, proposing much shorter lead times and greater production flexibility to our customers. It is like having a digital press with flexo costs. DaraghWhelan - Technical Director of Adare UK

23 Conventional Flexo Vs REVO Digital Flexo Conventional REVO No. of Set Ups 5 1 No. of Colours 6 7 No. of Ink Mixes: (Pantones) 10 0 No. of Plates: 30 7 Total Make Ready Material Mtrs: st Job Make Ready Time: 1 hr 30 mins 30 mins Run on Make Ready Time: 30 mins N/A Total Make Ready time: 3 hrs 30 mins 30 mins

24 Conventional Flexo Vs REVO Digital Flexo Conventional REVO No. of Set Ups 2 1 No. of Colours: 7 7 No. of Ink Mixes: (Pantones) 6 0 No. of Plates: 14 7 Total Make Ready Material Mtrs: st Job Make Ready Time: 1 hr 30 mins 30 mins Run on Make Ready Time: 30 mins N/A Total Make Ready time: 2 hrs 30 mins

25 Lots of special colours in one print

26 The most vibrant images ever printed

27 REVO Minimum specifications Extremely accurate register tolerances are needed to print with REVO also small negative types with 2-3 colours on top of each other. Accurate plate mounting is needed. Presses with accurate register performances are needed. Total colour consistency is a must to achieve PMS matching in production. Infinite Flower print units guarantee 100% colour consistency from 10 to 180 m/min. GTT anilox rollers guarantee worldwide that ink transfer tolerance between rollers is limited to less than 1%. Flexocure ANCORA inks, Cyrel DFUV/DPR photopolymer plates and FIT substrates guarantee standardized and tested quality for all the supplies globally, to obtain global colour consistency. AVT Helios makeready pressure control ensures accurate operator independent pressure consistency.

28 REVO Frequently Asked Questions Can I retrofit my existing flexo press? No, the REVO Set of Technologies is the best off-the-shelf package to start printing with REVO method, andgetting immediatelyallthe REVO benefits.

29 REVO Frequently Asked Questions When I print a 5 colours job (a process job, with only one additional PMS colour), do I need always to use 7 inks and seven plates? NO, REVO will use minimum number of inks and plates. Only a selection (and not all) of the 7 inks available will be required to reproduce the desired PMS. Can I print with just 4 process colours and print also PMS colours? YES, with REVO Technology you can print with 4 colours process inks and achieve up to 68% of PMS colours. Whatis the lifetimeof REVO 80 linesplate comparing standard DigitalFlexo? Same or better because the pressure control is automated

30 REVO Frequently Asked Questions When I print a specific PMS colour, do I always need to print 7 colours on top of each other? NO, any PMS colour will be reproduced with max 3 colours selected between the 7 colours available. Can I use my existing anilox rollers? NO, you need to buy REVO compatible GTT anilox rollers which can guarantee the consistent and standardized ink transfer needed to achieve REVO quality. Can I use my existing inks, substrates, press, inspection system? NO, you will not achieve the same accuracy in colour matching, the same quality in printing, the same consistency in the printed results, and you would not get all the combined, standardized advantages of the integrated REVO Set of Technologies and of Digital Automation. In the future the REVO Set of Technologies will be further extended.

31 REVO Frequently Asked Questions Who is going to make the plate for me? ADARE REPRO HOUSE can support you on Repro graphic file preparation for REVO standard. Contact Daragh Whelan The REVO Team will identify and propose you the closest REVO Service Point to your company. Please Contact DUPONT PACKAGING GRAPHICS: Mr. Carsten Bastian ESKO : Mr. Fredric Vanvinckenroye (fredric.vanvinckenroye@esko.com) Who is going to consult and qualify me or my service point on REVO? ADARE REPRO HOUSE Contact Daragh Whelan (daragh.whelan@adare.com)

32 REVO Frequently Asked Questions Can I make REVO plates in house? Yes, you need to buy Equinox program for 7 color separation and use HD flexo plate manufacturing process for Cyrel DFUV photopolymer plates.

33 The future of REVO Stay updated and visit occasionally the official REVO web site. ( REVO will advertise and publish all the news and technical innovations achieved in the coming months. REVO Contact List For all kind of support you can contact the following REVO members: ADARE : Mr. Daragh Whelan (daragh.whelan@adare.com) APEX GROUP of COMPANIES : Mrs. Jeanine Graat (jgraat@apex-europe.com) AVT : Mr. David Naisby (DavidN@AVT-INC.COM) DUPONT PACKAGING GRAPHICS: Mr. Carsten Bastian (carsten.bastian@dupont.com) ESKO : Mr. Fredric Vanvinckenroye (fredric.vanvinckenroye@esko.com) FLINT GROUP : Mr. Niklas Olsson (niklas.olsson@flintgrp.com ) Nuova GIDUE Srl : Mrs. Cristina Toffolo (cristina.toffolo@gidue.com) UPM RAFLATAC : Mr. Marko Tiainen (marko.tiainen@upmraflatac.com)

34 Thank you! The Revo Members